WO2008004733A1 - Tissu intercalaire et son procédé de fabrication - Google Patents

Tissu intercalaire et son procédé de fabrication Download PDF

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Publication number
WO2008004733A1
WO2008004733A1 PCT/KR2006/005828 KR2006005828W WO2008004733A1 WO 2008004733 A1 WO2008004733 A1 WO 2008004733A1 KR 2006005828 W KR2006005828 W KR 2006005828W WO 2008004733 A1 WO2008004733 A1 WO 2008004733A1
Authority
WO
WIPO (PCT)
Prior art keywords
yarn
fabric
lscy
dty
pile
Prior art date
Application number
PCT/KR2006/005828
Other languages
English (en)
Inventor
Pyung-Yul Park
Sang-Min Nah
Jong-Hyun Hwang
Original Assignee
Kolonglotech. Inc
Massachusetts Institute Of Technology
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kolonglotech. Inc, Massachusetts Institute Of Technology filed Critical Kolonglotech. Inc
Priority to US11/648,945 priority Critical patent/US7565821B2/en
Priority claimed from US11/648,945 external-priority patent/US7565821B2/en
Publication of WO2008004733A1 publication Critical patent/WO2008004733A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/56—Heating or ventilating devices
    • B60N2/5607—Heating or ventilating devices characterised by convection
    • B60N2/5621—Heating or ventilating devices characterised by convection by air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/58—Seat coverings
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/10—Open-work fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using knitted fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/128—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with silicon polymers
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
    • D10B2403/0213—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics with apertures, e.g. with one or more mesh fabric plies
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/08—Upholstery, mattresses

Definitions

  • the present invention relates to spacer fabrics, and more specifically to a spacer fabric with advanced cushionability, flexibility, and thermal conductivity, and a method of fabricating the same.
  • the D/R fabric is composed of two ground faces, and each ground consists of a front face and a back face.
  • each ground consists of a front face and a back face.
  • vertical pile yarns are created between ground faces simultaneously with the formation of the grounds.
  • Raw fabrics of the D/R fabric are produced by slitting the center of the pile yarns using a center-cutting knife, as shown in Fig. 7.
  • the D/R fabric has some advantages in that it is nice to touch, its stretchability can be controlled, and it is high in quality level. However, it has disadvantages such as difficulties in pattern expression and high costs.
  • Fig. 8 shows the structure and formation principle of T/C fabric. Referring to Fig.
  • the T/C fabric is knitted with one ground face that is immediately piled to create pile yarns.
  • the knitted pile yarns are pulled to form long pile yarns, and then, the pulled pile yarns are cut to form final pile yarns.
  • the surfaces of the pile yarns are subjected to finishing treatments to complete the T/C fabric as shown in Fig. 8.
  • the T/C fabric has advantages such as easiness in pattern expression, high stretchability, and low costs compared to its quality. However, it has disadvantages such as the lack of external attractiveness in appearance and roughness to touch.
  • Fig. 9 shows the structure and formation principle of F/W fabric.
  • the F/W fabric is fabricated through continuous repeat intersection of the warp yarn and the weft yarn.
  • the F/W fabric can be divided into two types as follows: a Dobby fabric having a single repeat intersection, and a Jacquard fabric having numerous single structures combined to form a double or a multiple structure.
  • the F/W fabric has advantages such as ease of pattern expression, relatively low weight, and ease of control and treatment. However it has disadvantages such as its not-so-attractive external appearance, harsh textural feel, and low stretchability.
  • Fig. 10 shows the structure and formation principle of C/K fabric.
  • the C/K fabric As a weft knitting cloth, the C/K fabric is formed through loops on the surface of raw material, where knitting is progressed horizontally. In this case, a pile is formed through loop cutting, and the surface of the pile is then uniformly treated during the shearing process.
  • Advantages of the C/K fabric lie in the ease of pattern expression and superior stretchability. However, it also has disadvantages such as an easiness to be frayed and weak tenacity.
  • weft knitted fabrics such as the C/K fabric and the S/P fabric are useful in respect of flexibility
  • warp knitted fabrics such as the D/R fabric and the T/C fabric are useful in respect of softness and cushionability
  • weaved fabrics such as the F/W fabric and the M/Q fabric are useful in respect of thermal conductivity.
  • the term 'seat' may be defined as an instrument with the purpose of supporting the human body.
  • a car seat means, in a narrow sense, a seat for an automobile, and in a broad sense, a seat for all moving vehicles.
  • a car seat is essentially differentiated from a general chair because it is continuously exposed to vibration and directly related to driving safety.
  • Some embodiments of the present invention provide a spacer fabric with advanced flexibility, cushionability, and thermal conductivity, comprising a top layer and a bottom layer formed by knitting Latent Self Crimping Yarn (LSCY) and Draw Textured Yarn (DTY), and multiple pile yarns formed between the top and bottom layers linking the two layers.
  • LSCY Latent Self Crimping Yarn
  • DTY Draw Textured Yarn
  • the LSCY is a side-by-side yarn containing one component or the combination of two components selected from the group consisting of polyethyleneterephthalate (PET), polytrimethyleneterephthalate (PTT) 5 polybutyleneterephthalate (PBT), and nylon;
  • the DTY is prepared by drawing polyester or nylon filament yarn;
  • the LSCY and DTY have a diameter of 75 to 400 Denier;
  • the pile yarn is a monofilament made of a component selected from the group consisting of polyester, nylon, acryl, metallic yarns, and carbon fibers, and having a diameter of 20 to 50 Denier.
  • Another embodiment of the present invention provides a method of preparing a spacer fabric with advanced flexibility, cushionability, and thermal conductivity, comprising: forming a top layer and a bottom layer by knitting Latent Self Crimping Yarn (LSCY) and Draw Textured Yarn (DTY), wherein the LSCY is a side-by-side yarn prepared by conjugated spinning using one or two components selected from the group consisting of polyethyleneterephthalate (PET), polytrimethyleneterephthalate (PTT), polybutyleneterephthalate (PBT), and nylon, and has a diameter of 75 to 400 Denier, and the DTY is prepared by drawing polyester or nylon filament yarn and has a diameter of 75 to 400 Denier; forming multiple pile yarns between the top and bottom layers linking the two layers, wherein the pile yarn is a monofilament made of a component selected from the group consisting of polyester, nylon, acryl, metallic yarns, and carbon fibers, and having a diameter of 20 to 50 Denier; and performing the finishing steps comprising
  • Still another embodiment of the present invention provides a car seat fabricated using the spacer fabric, wherein the car seat may contain an actuator having a moving effect and a heat transfer device such as a transfer electron device (TED).
  • TED transfer electron device
  • Fig. 1 is a schematic view showing the structure of a spacer fabric according to the present invention
  • Fig. 2 is a graph showing the comparison of the thermal conductivity of the surface of the spacer fabric depending on the hole size
  • Fig. 3 is a graph showing the comparison of the extension and the recovery of the surface of the spacer fabric depending on AMD hole size with fixing MD hole;
  • Fig. 4 is a graph showing the comparison of the extension and the recovery of the surface of the spacer fabric depending on MD hole size with fixing AMD hole.
  • Fig. 5 is a graph showing the comparison of extension and recovery of the surface of the spacer fabric depending on the average hole size;
  • Fig. 6 is a graph showing the comparison of fabric pile height and the compression recovery of the spacer fabric depending on M/C plate distance;
  • Fig. 7 shows a schematic view showing the structure of the D/R fabric
  • Fig. 8 shows a schematic view showing the structure of the T/C fabric
  • Fig. 9 shows a schematic view showing the structure of the F/W fabric
  • Fig. 10 shows a schematic view showing the structure of the C/K fabric
  • Fig. 11 shows the pile patterns
  • Fig. 12 schematically demonstrates the lay-out of the spacer fabric according to the present invention.
  • the term 'car seat' is used in a broad sense, that is, it means an instrument with the purpose of supporting the human body setting in all moving vehicles.
  • the object of the present invention is to provide a car seat with an advanced high-performance.
  • the device exhibiting such effects is to be installed underneath the fabric material of the car seat and therefore has indirect effects on the driver.
  • the fabric acts as an intermediary material with the role of transmitting the abilities of the device to the driver in a more smooth, efficient, and safe manner.
  • the characteristics required for the car seat include the following: 1) stretchiness to aid the operation of the pusher connected to the SMA actuator; 2) softness of the cushions to decrease discomfort factors caused by the stiffness of the Peltier's device; and 3) high thermal conductivity to raise the thermal efficiency by more rapidly heating and cooling.
  • the present inventors found, through various tests to prepare a car seat fabric having the above three characteristics of flexibility, cushionability, and thermal conductivity, that a fabric material that satisfies the above characteristics is a spacer-type fabric prepared with Latent Self Crimping Yarn (LSCY), Draw Textured Yarn (DTY), and monofilament yarns, to complete the present invention.
  • the main goal of the present invention is to develop a seat fabric capable of maximizing the exhibition of the effects provided by actuator technologies.
  • the actuator technologies may be broadly divided in two classes. One would be the Transfer Electron Device (TED) technology that effectively reduces the adverse effects of the extreme surroundings of heat in summer or cold in winter. The other is the technology regarding the movement of the actuator that creates a massaging effect, soothing the driver's pain in the hip and thighs caused by long distance driving, to provide comfort to drivers.
  • the effects of the actuator technology can be transferred to the drivers essentially passing through the seat fabric, thereby requiring the development of the optimal car seat fabric.
  • the mainly required properties of the car seat fabric to achieve the above objects are as follow.
  • the flexibility plays a role of transferring the massaging movement of the actuator to the human body.
  • both vertical and horizontal stretchabilities are not achieved, the individual performance of the motion would be reduced, and thereby it is possible that the efficiency of the sectionalizing program (the movement order, the movement program, etc.) may be reduced.
  • the quantitative capability for flexibility can be verified through such testing methodologies as elongation at specified loads and the elongation set.
  • the actuator is generally located beneath the seat cloth for exhibiting the two major functions, which, however, may cause some discomfort to the driver. In other words, the driver may feel the stiffness of the device causing the driver to suffer. In order to overcome such a problem, it is necessary to give cushionability to the car seat fabric.
  • the cushionability should be exhibited by the performance of the car seat fabric itself without additional sponge support for the reasons as follow.
  • the sponge is laminated onto the back in order to increase comfort and fix the form of the fabric.
  • this sponge is a PU foam, which is a polymer material with the ability of self- maintenance against heat through latent heat. It could potentially cause a hindrance to the goal of 'quick response', and in order to solve this problem, it is necessary to develop a cushion force within the seat cloth itself. The cushion force is measured by the ability to recover quickly from compression and through physical softness.
  • Thermal conductivity is the quantitative measurement of how effectively heat/cold is transferred from the source to the target, and supports the performance exhibition of the quick cooling and heating, which is one of the major goals of this invention.
  • the thermal conductivity and air permeability are relatively compared in order to measure each other.
  • the abrasion resistance and the color fastness of common polyester yarn and polytrimethyleneterephthalate (PTT) may be also considered as important properties for the present fabric.
  • the present invention provides a spacer fabric with advanced flexibility, cushionability, and thermal conductivity, including a top layer and a bottom layer formed by knitting Latent Self Crimping
  • the present invention provides a method of preparing the spacer fabric with advanced flexibility, cushionability, and thermal conductivity, including: knitting LSCY and DTY to form a top layer and a bottom layer; forming multiple pile yarns using monofilament yarns between the top and bottom layers that link the two layers; and performing finishing processes including a stabilizing step, a pre-setting step, a dyeing step, a final setting step, and a resin treatment step.
  • the spacer fabric is found to have superior tensile, elongation, extension, thermal conductivity, and air permeability properties. Therefore, the present invention provides a spacer fabric type fabric.
  • the LSCY is a material having the characteristic that a crimping property is exhibited by a thermal treatment after processing, while it is not exhibited prior to the processing. Therefore, the LSCY provides flexibility to the prepared fabric. In particular, the LSCY prepared by conjugated spinning in the form of two components side-by-side may have more superior flexibility through the crystal orientation control.
  • the LSCY may be a side-by-side yarn containing one component or the combination of two components selected from the group consisting of polyethyleneterephthalate (PET), polytrimethyleneterephthalate (PTT), polybutyleneterephthalate (PBT), and nylon.
  • PET polyethyleneterephthalate
  • PTT polytrimethyleneterephthalate
  • PBT polybutyleneterephthalate
  • nylon nylon
  • the combination ratio may vary depending on the use and the desired property of the prepared fabric, and be preferably 1:2 to 2:1 by weight.
  • the LSCY may be a side-by-side yarn prepared by conjugated spinning using one component with mixing an orientation restrainer to only one side.
  • the orientation restrainer may unlimitedly include all materials conventionally used to control the orientation degree, and for example, may be selected from the group consisting of poly methyl metacrylate (PMMA), methyl metacrylate (MMA), poly ethylene (PE), poly propylene (PP), and the like.
  • the amount of the orientation restrainer used is preferably 0.01 to 10 wt%.
  • the LSCY may be a side-by-side yarn prepared by conjugated spinning using two components having different peculiar viscosity and shrinkage, such as PET and PTT.
  • the peculiar viscosities of PET and PTT may be 0.5 to 0.7 cps and 0.9 to 1.1 cps, respectively, and the difference of shrinkage therebetween may be 30 to 70%.
  • the same substances having the different peculiar viscosity and shrinkage may also be used.
  • the LSCY is prepared using an orientation restrainer to only one side, or the combination of two components having the different peculiar viscosity and shrinkage, more superior flexibility may be obtained through controlling the orientation degree.
  • the molecular weight of the polymers used as components of the LSCY may be preferably 10,000 to 20,000 in the case of a low-viscosity polymer, and 25,000 to 50,000 in the case of a high-viscosity polymer, but not limited thereto.
  • the DTY may be prepared by drawing a polyester or nylon filament to generate twists, and thereby obtaining advanced flexibility, softness, and touch feeling.
  • the DTY may be prepared by drawing polyester pre-oriented yarn (POY), double twisting two or more folds of the obtained drawn yarn at the twist ratio of 1OZ to 5OZ, first heating the twisted yarn at 180 to 200 ° C , and second heating the first heated yarn at 190 to 210 ° C .
  • the weight ratio between the LSCY and the DTY may be preferably 1 : 0.75 to 2 (LSCY weight : DTY weight).
  • the LSCY should secure a proper space during a heat-setting process, and for this purpose, the DTY that functions as a support in texture is necessary to be mixed at a proper portion. Therefore, considering the above, it is preferable to settle the ratio between the LSCY and the DTY to the above range.
  • the diameters of the LSCY and the DTY are also important factors that affect the structure and the property of the fabric to be prepared. Therefore, to achieve the properties required for the fabric according to the present invention, the diameters of the LSCY and the DTY are preferably 75 to 400 Denier, and more preferably, 180 to 350 Denier. Since the fabric is necessary to secure a minimal volume to satisfy the requirements of flexibility and compression recovery required for the car seat cloth, it is preferable to settle the diameters of the LSCY and the DTY to the above range. When the diameters of the LSCY and the DTY are greater than 400 Denier, it is impossible to weave a spacer fabric.
  • the top and the bottom layers may have holes having a proper size, leading to more improved flexibility (extension), air permeability, recovery, and thermo conductivity of the fabric.
  • the advantageous hole diameter is preferably 3 to 5 mm
  • the ratio of machine direction (MD), i.e., a weaving direction, to across machine direction (AMD), i.e., a vertical direction to the weaving direction, of the hole size is preferably 1 to 1.5, and more preferably 1, leading to a circular shape.
  • the holes may be formed on only the top layer, or both of the top and bottom layers.
  • the sensitivity of the thermal conductivity obtained by variation of AMD holes is higher than that by variation of MD holes by about 2 times. In other words, it is more effective to control the conditions for thermal conductivity by variation of the AMD holes size than by variation of the MD holes size.
  • the fabric is in the form of a spacer fabric having multiple pile yarns between the top and the bottom layers.
  • the pile yarns link the top and the bottom layers, and thereby a proper space is obtained therebetween, contributing to thermal conductivity and cushionability, and the two layers are mechanically supported and balanced, contributing in shapeability and flexibility as well. Therefore, in the pile yarn, rigidity and recovery should be basically secured. For this reason, the pile yarn should be made of a proper material and have a proper diameter.
  • the pile yarn may be prepared using a monofilament yarn made of a component selected from the group consisting of polyester, nylon, acryl, and conductive yarns including metallic yarns and carbon fibers.
  • the diameter of the monofilament consisting in the pile yarn is 20 to 50 Denier, and more preferably 30 Denier.
  • the structures created by the pile yarns linking the top and the bottom layers include a straight pattern, a cross pattern, and a semi-cross pattern (See Figure. 1).
  • the straight pattern is a structure knitted on the same wale
  • the cross pattern is a structure knitted by moving 2 wales
  • the semi-cross pattern is a structure knitted by moving one wale.
  • the semi-cross pattern has a higher pile height, elasticity, and compression recovery force than the others, and therefore, the semi- cross pattern may be preferably employed in the present invention. More preferably, the pile yarn may be in the semi-cross pattern having the pile structure forming coordinates of 21100112 and 01122110.
  • the content of the pile yarns for the weights of the LSCY and the DTY may be preferably 1 : 0.75 to 2 : 0.5 to 1.5 (LSCY weight : DTY weight : pile yarn weight).
  • the thickness of the spacer fabric may be determined by the pile height, which may be controlled by the machine (M/C) plate distance in the initial state, where, as the pile height becomes higher, the compression recovery force becomes lower.
  • M/C plate distance is necessary to be controlled to a proper range.
  • the M/C plate distance may be 7 to 9 mm, and preferably, 8 mm (See Fig. 6).
  • the finishing step provides final properties to the spacer fabric, the shape thereof is created in the above knitting process, and may include a stabilizing step, a pre-setting step, a dyeing step, a final setting step, and a resin treatment step.
  • the stabilization step is to secure a proper space for the flexible expression of the yarns by smoothly enlarging the spacer fabric within optimal conditions, thereby obtaining flexibility of the fabric. Therefore, the key of the process is the enlargement of the fabric within optimal conditions. That is, the stabilization step is a process for the purpose of improving the stretch capability of the fabric. For this purpose, the stabilization step may be performed under the conditions of a reaction temperature of 100 to 140 ° C, an enlargement rate of 15 to 25m/min, and a fabric width enlargement of 5 to 10%.
  • the pre-setting process is a heat treatment step, which provides a smooth dyeing process by fixing the shape of the fabric and plays a role of re-obtaining the stretch capability obtained in the stabilization step.
  • the presetting step may be performed under the conditions of a reaction temperature of 150 to 190 0 C and an enlargement rate of 15 to 25m/min, more preferably 20m/min.
  • the dyeing step is to apply a commercially valuable color to the fabric.
  • This step may use a disperse dye and/or an acidic dye, and further use one or more additives selected from an antistatic agent, a dispersing agent, a nonflammable agent, and the like.
  • each additive may be preferably used in the amount of 0.1 to 3 wt%.
  • the dyeing step may be preferably performed at 100 to 130 ° C for 10 to 60 minutes.
  • the final setting step is the final heat setting process, and plays a role of re- stabilization of the changed stretch capability and fixation of the shape after the dyeing process is performed.
  • this step may be preferably performed at the temperature of 130 to 160 ° C and the rate of 15 to 25m/min, preferably, 20m/min.
  • the resin treatment step is to obtain flexibility, stretch capability, cushioning capability, and softness.
  • the resin treatment step is performed by treating with a resin containing a mixture of a carboxyl functional silicone softener and a silicon emulsion, a cation-based active surfactant compound, and an anion active solution, at the mixture ratio of 1 : 1 to 3 : 2.
  • the resin treatment may be performed simultaneously with, or after, the final setting step under the same conditions as the final setting step.
  • the present invention provides a car seat fabricated by using the spacer fabric according to the present invention.
  • the car seat of the present invention provides comfortableness to drivers due to the superior cushionability of the spacer fabric of the present invention; when equipped with an actuator having a moving (massage) effect for the human body, effectively transfers the actuator moving effect to the drivers due to the superior flexibility of the spacer fabric; and when equipped with a heating and/or cooling device such as a TED, effectively exhibits a sufficient heating/cooling effect due to the superior thermal conductivity of the spacer fabric.
  • POY 250/48-SD (Kolon, Korea) was drawn at the temperature of 150 to 22O 0 C and the rate of 300 ⁇ 500m/min. Two of the drawn yarns were double- twisted into 2-ply yarns through 1 heater setting at the twist ratio of 3OZ, to prepare a DTY 300/96- IH yarn.
  • the M/C used was a pin type, and the process was performed under the condition of the yarn speed being 140m/min and the heater temperature being 200 0 C.
  • the PET&PET LSCY which is a side-by-side type PET and PET yarn prepared by mixing an orientation restrainer to only one side of the yarn during conjugated spinning, was provided from KOLON IND. INC. (Korea).
  • the PTT&PET LSCY which is a side-by-side type PTT and PET yarn prepared by using PTT and PET having different peculiar viscosity and shrinkage in conjugated spinning, was provided from KOLON IND. INC. (Korea).
  • the properties of the yarns provided as above were measured by the following methods.
  • the hank was made at a denier creel machine with 10 as the number of rotations (the take-up stress is nominal denierxl/lOg).
  • the length (L 0 ) of the hank was measured while hanged, with an initial load (nominal denier ⁇ l/20g) and a static load (nominal denierx2g).
  • the hank was hung and the initial load was heated for 30 minutes in a 100 ° C water vessel. Then, it was taken out and moisture was eliminated from the surface, and the hank was left alone for 12 hours at atmospheric conditions. After this, the length (L 1 ) of the hank was measured, once again being hung up with initial load and the static load.
  • the properties of elongation and tenacity were measured by the test described in KS K0323.
  • the yarns were elongated until fractured, and the elongation and the force corresponding thereto were measured using a tensile tester.
  • Table 1 shows the physical properties of the yarns that were produced as above. [Table 1]
  • Table 1 shows data obtained by measuring the physical properties of the yarn itself. As shown in Table 1, the LSCY is far superior to others in the Sr ratio, which is a measurement of the shrinkage percentage during the dyeing process. Further, highly shrinking yarn is outstanding in the CR ratio at the atmospheric conditions (2O 0 C, RH 70), while the LSCY showed better results than others under high temperatures with a heat treatment of 18O 0 C. It can be confirmed that the PTT&PET LSCY yarns are the most efficient with regards to the shrinkage ratio and crimp recovery force because the heating is an indispensable process in producing the final end product.
  • Example 2 Preparation of Spacer Fabric
  • the LSCY PTT&PET Yarn and the DTY 300/96-1H were knitted at the ratio of 1 :0.75 to 1:2 using a D/R machine (KARL MAYER Textilmaschinenfabrik GmbH, Germany) as a knitting machine at 500rpm, to form a top layer and a bottom layer.
  • a D/R machine KARL MAYER Textilmaschinenfabrik GmbH, Germany
  • Polyester monofilaments (Saehan Industries Inc. Korea) were knitted between the top and the bottom layers to create pile yarns linking the two layers.
  • the pile yarns were prepared so as to have the diameters of 20 and 30
  • FIG. 12 The fabric count and thickness of the fabric as prepared above are schematically demonstrated in Figure 12.
  • a top layer (surface or front) I 5 a middle layer (pile) 2, and a bottom layer (base or back) 3 of the space fabric of the present invention are demonstrated.
  • the prepared spacer fabric containing the top and bottom layers and pile yarns was subjected to the stabilization step under the conditions of a fabric width enlargement of 10%, a rate of 20m/min, and a temperature of 120 ° C, and then a pre-setting step at 170 ° C and 20m/min. Thereafter, a dyeing step was performed under the following conditions. a. Increase 1 ° C/min to 80 ° C b. Leveling at 80 ° C during 15min c. Increase 1.5 ° C/min to 110 0 C d. Dyeing at 110 ° C during 30min e. Natural cooling.
  • a final setting step was perfprmed at 150 ° C and 20m/min.
  • the resin containing, as a softening agent, SF-73K (NICCA), which is a cation-based active surfactant compound and deatron AS-20(NICCA), which is an anion active solution in the combination ratio of 2:1 (SF-73K:AS-20) was treated at the pick-up ratio of 1 to 5%.
  • Wefts were mix-weaved on beamed wraps (DTY 450De, Air Textured Yarn(ATY), 520De) in a desired pattern to design the fabric. Various yarns were used as the wefts.
  • the prepared raw fabric was finished by heating and coating processes to produce the final F/W fabric.
  • Each DTY (Polyester, 150De or 300De) was knitted with a cheese cone into C/K raw fabric having a circular knit structure in various patterns.
  • the prepared raw fabric was subjected to heat setting and dyeing processes to produce the final C/K fabric.
  • Ground yarns (Polyester, 75De) were beamed and desired yarns as pile yarns (DTY 150De) were provided and knitted, producing a cut-type tricot product. Heating setting, dyeing, and cutting processes were performed, followed by pile shearing and brushing processes, producing the final T/C fabric.
  • the D/R crease fabric was produced by the same method as used in producing the D/R fabric, except arranging the LSCY at the ground, to give an excessive stretch capability, thereby producing a wrinkled fabric.
  • the tensile strength and elongation were measured by the Labeled strip method. From each of the fabrics prepared in Example 2 and the comparative examples, five samples 55mm wide and about 250mm long were cut in warp and weft directions respectively. Approximately the same number of threads were removed from both edges in order to make the width 50mm. Marks were placed 100mm apart in the lengthwise center, later to be used during the test. Here, a tensiron type tension tester (Tensile Machine Instron 4444, Instron), or an equivalent was used, and the sample was gripped by the jaw and placed. A proper initial load (which is defined as the load necessary for stretching out artificial crumples and slackness) was applied so as to place the thread correctly in a vertical line with a 150mm distance between the jaws.
  • Example 2 From each of the fabrics prepared in Example 2 and the comparative examples, three samples (50mm in width and 250mm in length) were cut in both warp and weft directions. Marks were placed 100mm apart in the center of the samples, and each sample was placed in the Martens fatigue tester with a jaw distance of 150mm. Slowly, a load of 78.4N (8kgf) (including the lower clamp weight) was applied, and then left standing for 10 minutes with the load applied, determining the distance between the marks. Then, the clamps were removed to relieve the samples from the load, they were allowed to stand on a flat bench for 10 minutes, and then the distance between the marks was determined. The elongation at specified load and the elongation set were calculated by the following formula, and the obtained results are shown in Table 6.
  • Cushion force was measured through the testing method for carpet as described in KS K 1018. From each of the fabrics prepared in Example 2 and the comparative examples, five (5) sheets of 250x250mm were cut. A compression recovery tester (cloth thickness measuring apparatus 2046-08, Mitutoyo) was used. The thickness (mm) of the sample was measured after pressurization at 2 to 4 kPa for 30 seconds under regular pressure and then for 5 minutes under a final pressure (defined as 98kPa unless otherwise noted). Then, the load was removed, and the samples were left alone for 5 minutes. The thickness (mm) was measured after further pressurization for 30 seconds.
  • Thickness reduction (%) (t ⁇ -t' ⁇ )/t ⁇ ⁇ l ⁇
  • t ⁇ thickness at the regular pressure before the pressurization (mm)
  • tl thickness at the final pressure after letting alone for 5 minutes
  • t'O thickness at the pressurization till the settled pressure after removal of load (mm)
  • Thermal Conductivity was measured by two methods. One measured the thermal conductivity itself, wherein the thermal conductivity coefficients of the two-dimensional fiber group including both of weaved and knitted fabrics were measured. The other measured the air permeability including the factors of conductivity, convection, and radiation, wherein the quantity of air passed through the test samples. Also, thermal conductivity is predicted by the thermal flow owing to the temperature gradient.
  • thermal conductivities of the test samples were measured by the test method of thermal transmittance of textile fabrics (KS K 0466).
  • KS K 0466 the test method of thermal transmittance of textile fabrics
  • the thermal conductivity represents the working direction or working transfer amount per unit temperature gap between two plans and per unit area. Therefore, thermal conductivity is obtained by the distance between the plans multiplied by the thermal transfer coefficient. The dimension ends up being W/m-k. The obtained results are shown in Table 6.
  • Air permeability was measured by the determination of the permeability of textile cloth to air (KS K 0570). From each of the fabrics prepared in Example 2 and the comparative examples, three test samples of 180x180 mm were cut and attached to one end of a Flagire type ventilation tester. The suction fan was adjusted by rheostat so, that the tilting barometer stands at a pressure of 12.7 mm water head. The airflow passing through the sample was read in m-C/cm2-sec. in accordance with the table attached to the tester on the basis of the pressure of the vertical barometer at that time and the type of air orifice used. The average of three readings was considered as the final result, which is shown in Table 6.
  • the load herein means the load acting on a single arm. The test was conducted by the load action on both arms
  • the color fastness may be divided into two types to rubbing with a dry cloth and a sweat cloth.
  • the color fastness to rubbing with a dry cloth was measured as follows. Two samples of 25mm in width and 220mm in length were cut parallel to the warp direction and placed firmly on the stand of a friction tester (intended to be JIS L 0823 type II; for this test, the test sample stand of 200mm radius semi-circular form was used). The samples were securely held and the tester friction shoe was covered with white cotton cloth ("Cotton No. 3" known as "Shirting No. 3", specified in Table 2 under JIS L 0803) of 50mm X 50mm. A load of 4.9N (500gf) was applied to the friction shoe. The shoe was driven back and forth 100 cycles with a stroke of 100mm at the rate of 130cycles/m.
  • JIS K 9010 sodium phosphate, dibasic (12 hydrate)], 8g
  • Class 1 or better of JIS K 8150 (Sodium chloride), 8g;
  • MD Machine Direction (MD).
  • AMD Across Machine Direction
  • the results shown in Table 6 are as follows.
  • the F/W and spacer fabrics are superior in tensile properties.
  • the C/K and T/C fabrics are superior in elongation property.
  • the C/K, spacer fabric, and pleated fabric are superior in extension property.
  • F/W, spacer fabric, and pleated cloth are superior in elongation set property.
  • the resulted value for the F/W fabric was too insignificant to have a meaning.
  • the spacer fabric and the T/C fabric are superior in abrasion property.
  • the T/C and spacer fabrics are superior in thermal conductivity property.
  • the C/K and spacer fabric are superior in air permeability. In conclusion, the spacer fabric has the most preferable values than any other fabrics tested.
  • the design capable of being expressed as the spacer fabric can be realized by the formation of holes on the top layer of the surface. Such holes can increase the thermal conductivity of the fabric. Also, a circle is the most stable and stretchable design. The efficiency of the spacer fabric is tested based on the circle form. The circle diameter of one direction was changed under conditioning at the warp direction (MD) or the weft direction (AMD) individually, to produce the spacer fabric as in Example 2. The results are shown in Table 7 and Figures 2 to 5. [Table 7] The results of spacer fabric by a hole size
  • the changed ratios of the AMD holes and the MD holes are compared. This reveals that the sensitivity of thermal conductivity by variation of the AMD holes is higher than that by variation of the MD holes by about 2 times. In other words, it is more effective to control thermal conductivity by variation of the AMD holes.
  • the average hole size represents the average lengths (mm) of the MD and AMD holes.
  • Fig. 5 graphs the measured values at each point of the average hole size.
  • the hole range makes the optimization of thermal conductivity, extension, and recovery.
  • the average value is about 3 to 5 mm.
  • fixation values of the MD and AMD holes are 4.5 and 3, respectively.
  • the cross pattern has a high initial fabric pile height. However, it is confirmed that the semi-cross pattern has a higher pile height and elasticity than the others because of the difference of compression recovery force. It is inferred that the knitted stitch has a distance of 1.15mm with side wale as the best value at the constitution of the cross-sectional relation amongst each other for support and balance. However, excessive swinging to other side had a bad influence on compression recovery.
  • the physical property of the spacer fabric was tested by the measurement of the LSCY ratio.
  • the spacer fabric was prepared varying the portion of the LSCY as in Example 2. The results are represented in Table 11. [Table 11] The physical property of spacer fabric by yarn ratio
  • the knitting process and the finishing process of the yarn portion of 20, 30, 40, 50, and 80 wt% can be various depending upon the pattern or design. In other words, problems of working feasibility are caused by excessive contraction (about 50wt%) and pleat.
  • the NSM5004A was a knitted fabric made by LSCY300. However, regardless of the fact that NSM5001B is a knitted fabric made by LSCYl 80, compression recovery and cushion properties are inversely related. Regarding extension, NSM5004C is superior, while the NSM5004B is superior regarding set (MD, AMD) and cushioning comparatively, although both have the same pattern and design.
  • the knitting or weaving process makes the basic form of raw white fabric, while the finishing process plays a role in stabilization of the form and expression of the final function of the seat cloth.
  • the finishing process was divided into a total of 4 steps, those being stabilization, PS, dyeing, and FS.
  • Stabilization was fixed at 12O 0 C and PS 17O 0 C chamber temperature.
  • the dyeing process was performed at the temperature range of 100 to 13O 0 C.
  • the next process, FS is performed at 14O 0 C and 16O 0 C individually.
  • the rest of the conditions are shown in the following Table 15.
  • the working method of the dyeing process at HO 0 C is as follows: a. Increase 1 ° C/minto 80 ° C b. Leveling at 80 ° C during 15min c. Increase 1.5 ° C/minto 110 ° C d. Dyeing at 110°C during 30min e. Natural cooling.
  • the former step was fixed as follows: stabilization 12O 0 C, PS 17O 0 C, dyeing HO 0 C, and FS temperature range of 130 to 16O 0 C.
  • the results are shown in Table 16. [Table 16] The result of the Pre-Setting Process
  • the resin treatment process takes place during the FS step.
  • the conditions for this process are as follows: stabilization 12O 0 C, PS 17O 0 C, dyeing HO 0 C, and FS 15O 0 C.
  • the main resin is a softening agent: Silsoft AM-2 consisting of a carboxyl functional silicone softener, SF-73K consisting of a silicon emulsion and cationic active surfactant compound, and Deatron AS-20 consisting of an ion active solution. These were compounded with the pick-up ratio of 1 to 5%.
  • the results are represented in Table 17. [Table 17] The result of the Resin Treatment Process
  • the High Shrinkage Yarn had a higher value for CR at atmospheric conditions (2O 0 C, RH70). However, LSCY showed the most superior results under a heated setting (18O 0 C). In other words, the PTT&PET LSCY had the best results in the yarn's shrinkage ratio and crimp recovery force.
  • the spacer fabric was better than any other fabric (F/W, C/K, T/C, D/R, and D/R pleated fabrics) in the results of functional testing by fabric type.
  • the physical properties compared relatively were tensile/elongation, extension/set, stretchability, thermal conductivity, and air permeability.
  • the sensitivity of the thermal conductivity of the spacer fabric by AMD hole variation was about twice as much than that of MD hole variation. That is, thermal conductivity by AMD hole variation was much more effective.
  • the spacer fabric had the optimum condition of thermal conductivity, extension, and recovery with the 3 to 5mm hole range. The results were correlated upwards when the hole shape was in circles instead
  • the optimum conditions according to the test results by the finishing process step are as follows.
  • the optimum hybrid ratio of the compounding resin, SF-73K and AS- 20, for the resin treatment process was 2:1, and the best pick-up ratio was 1%.
  • the major specification and physical properties of the spacer fabric are in Table 18. [Table 18] Working conditions and Physical Properties
  • the spacer fabric according to the present invention is useful as a car seat fabric.
  • the spacer fabric according to the present invention is applicable to a car seat equipped with an actuator and a heating/cooling apparatus inside, due to the advanced flexibility for transferring the actuator moving effect to the body, the increased cushionability for minimizing the hardness of the surface of the device, and the high thermal conductivity for effectively and quickly transferring the heating/cooling effect to the body.

Abstract

La présente invention concerne un tissu intercalaire dotée de propriétés de pointe en matière de capacité d'amortissement, d'élasticité et de conductivité thermique, ainsi que son procédé de fabrication. Ce tissu intercalaire convient pour des sièges de voiture. Plus particulièrement, il convient pour un siège de voiture doté d'un actionneur et d'un dispositif intérieur de chauffage/refroidissement compte tenu de son élasticité supérieure pour le transfert au corps de l'effet de déplacement de l'actionneur, de sa capacité d'absorption accrue atténuant la dureté de la surface du dispositif et sa conductivité thermique élevée assurant un transfert efficace au corps de l'effet de chauffage/refroidissement.
PCT/KR2006/005828 2006-07-07 2006-12-28 Tissu intercalaire et son procédé de fabrication WO2008004733A1 (fr)

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US60/819,083 2006-07-07
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3141646A1 (fr) * 2015-09-03 2017-03-15 Müller Textil GmbH Tissu tridimensionnel, section de tissu tridimensionnel et element d'habillage pouvant etre chauffe
CN106906562A (zh) * 2017-02-24 2017-06-30 宁波科彩织造有限公司 高弹力革基布的生产工艺

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5651847A (en) * 1993-02-12 1997-07-29 Hoechst Ag Double-face circular knit
WO2006027794A2 (fr) * 2004-07-16 2006-03-16 Reliance Industries Limited Fils etires d'excellente texture a sertissage automatique et leur procede de production

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5651847A (en) * 1993-02-12 1997-07-29 Hoechst Ag Double-face circular knit
WO2006027794A2 (fr) * 2004-07-16 2006-03-16 Reliance Industries Limited Fils etires d'excellente texture a sertissage automatique et leur procede de production

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3141646A1 (fr) * 2015-09-03 2017-03-15 Müller Textil GmbH Tissu tridimensionnel, section de tissu tridimensionnel et element d'habillage pouvant etre chauffe
CN106906562A (zh) * 2017-02-24 2017-06-30 宁波科彩织造有限公司 高弹力革基布的生产工艺

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